Classifications

• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
  • D01F1/00—General methods for the manufacture of artificial filaments or the like
  • D01F1/02—Addition of substances to the spinning solution or to the melt
  • D01F1/10—Other agents for modifying properties
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
  • D01D5/00—Formation of filaments, threads, or the like
  • D01D5/253—Formation of filaments, threads, or the like with a non-circular cross section; Spinnerette packs therefor
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
  • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
  • D01F6/02—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
  • D01F6/04—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds from polyolefins
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
  • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
  • D01F6/58—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products
  • D01F6/60—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from polyamides
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
  • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
  • D01F6/58—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products
  • D01F6/62—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from polyesters
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
  • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
  • D01F6/44—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds as major constituent with other polymers or low-molecular-weight compounds
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
  • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
  • D01F6/88—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polycondensation products as major constituent with other polymers or low-molecular-weight compounds

Definitions

• the present disclosure relates to a soil resistance-affecting additive and synthetic fibers made therefrom having enhanced soil resistance.
• the present disclosure also relates to articles of manufacture prepared from these fibers and methods for their production and use.
• U.S. Patent 5,882,762 to Goeman discloses carpet yarn comprising a plurality of filaments of thermoplastic polymers with a fluorochemical or non-fiuorochemical hydrophilicity imparting compound dispersed within the filaments. It was found that the presence of the hydrophilicity imparting compound in the filaments allowed production of carpet yarn with a reduced amount of spin finish or even without the spin finish normally required. Carpets produced using such yarn were less susceptible to soiling.
• U.S. Patent 8,247,519 discloses articles fabricated from polyamides and comprising fluoroether functionalized aromatic moieties with soil and oil resistance.
• U.S. Patent 8,304,513 discloses soil resistant polyester polymers, particularly
• poly(trimethylene terephthalate) comprising fluorovinylether functionalized aromatic repeat units.
• U.S. Patent 8,697,831 discloses soil resistant polyamides, particularly nylon 6,6 and nylon 6 comprising fluoroether functionalized aromatic repeat units.
• An aspect of the present invention relates to a synthetic fiber comprising a first fiber forming polymer, and a soil resistance-affecting additive.
• the soil resistance-affecting additive is present in the fiber at a range from about 0.1 to 10 percent by weight.
• At least a portion of the soil resistance-affecting additive is present on the surface of the fiber. Preferred is that this portion present on the surface is sufficient to impart soil resistant properties to the fiber.
• At least a portion of the soil resistance-affecting additive is not polymerized with first fiber forming polymer.
• At least a portion of the soil resistance-affecting additive has bloomed to the surface of the fiber.
• the first fiber forming polymer of the synthetic fiber is a polyamide, a polyester, or a polyolefm, or any combination thereof.
• the soil resistance-affecting additive of the synthetic fiber is an aromatic sulfonate or an alkali metal salt thereof.
• the soil resistance-affecting additive is a polymer.
• Another aspect of the present invention relates to a synthetic fiber comprising a first fiber forming polymer, a second polymer and a soil resistance-affecting additive.
• the first fiber forming polymer is present in a range from about 80 to 99 percent by weight; the second polymer is present in a range from about 0.2 to 10 percent by weight; and the soil resistance-affecting additive is present in the fiber at a range from about 0.1 to 10 percent by weight.
• the second polymer of the synthetic fiber has a melting point which is less than the melting point of the first fiber forming polymer and/or does not cause the synthetic fiber to fibrillate.
• the second polymer is a polyolefm, a polylactic acid or a polystyrene or any combination thereof.
• the soil resistance-affecting additive of the synthetic fiber is an aromatic sulfonate or an alkaH metal salt thereof.
• Another aspect of the present invention relates to articles of manufacture, at least a portion of which comprises one or more of these synthetic fibers.
• Nonlimiting examples of these articles of manufacture include yarns and fabrics formed from the synthetic fibers and carpets formed from the yams.
• Yet another aspect of the present invention relates to method for producing a synthetic fiber with enhanced soil resistance.
• the method comprises forming a polymer melt of a first fiber forming polymer and a soil resistance-affecting additive.
• the soil resistance-affecting additive is present in a range from about 0.1 to 10 percent by weight.
• a synthetic fiber is then formed from the polymer melt.
• the method comprises forming a polymer melt comprising a first fiber forming polymer and a masterbatch compound.
• the masterbatch compound comprises a second polymer and a soil resistance- affecting additive.
• the first fiber forming polymer is present in a range from about 80 to 99 percent by weight, and the masterbatch compound is present in a range from about 0.2 to 20 percent by weight.
• a synthetic fiber is then formed from the polymer melt.
• FIG. 1 is a plot which shows soiling performance after the carpet samples were hot water extracted before they were soiled. This plot indicates the durability of the soiling performance of the carpet samples. As indicated in FIG. 1, the examples with the inventive embodiments performed the best after HWE treatment.
• FIG. 2 is a plot of colorimetric L* progression upon the soiling and vacuum cleaning (S&V). and hot water extraction (HWE) cycles of a single set of carpets. H denotes that this carpet was pre-HWE 3X before the testing to mimic scouring.
• FIG. 3 is a SEM micrograph of a triloba! filament from an embodiment of the current invention. Depicted is pigmented 1.0wt% dimethyl-5-sulfoisophthalate, sodium salt (NaSIM) in a polyester fiber where the masterbatch carrier of the NaSIM is polypropylene.
• FIG. 4 is a set of SEM micrographs and XDS spectra of longitudinal sections of an embodiment of the current invention. Depicted is a trilobal filament of NaSIM in pigmented PET where the masterbatch carrier of the NaSIM is polypropylene.
• FIG. 5 is a SEM micrograph of an example of an embodiment of the current invention. Depicted is a trilobal filament of pigmented 0.5wt% 5-sulfoisophthalic acid, sodium salt (SSIPA) in a polyester fiber that was added with a polypropylene masterbatch carrier.
• SSIPA 5-sulfoisophthalic acid, sodium salt
• fibers with enhanced soil resistance are provided by this disclosure.
• the synthetic fiber comprises a first fiber forming polymer and a soil resistance-affecting additive.
• first fiber forming polymers which can be used in this embodiment include, but are not limited to, polyamides, polyesters, and polyolefins and any blends or combinations thereof.
• Suitable polyamides include fiber forming polyamides known in the art to be suitable for the formation of bulked continuous filament fibers, having sufficient viscosity, tenacity, chemical stability and crystallinity to be at least moderately durable in such application.
• the polyamide may be selected from the group consisting of nylon 5,6; nylon 6,6; nylon 6; nylon 7; nylon 11; nylon 12; nylon 6/10;, nylon 6/12; nylon DT; nylon 6T; nylon 61; and blends or copolymers thereof.
• the polyamide is nylon 6,6 polymer.
• Suitable polyolefins include polypropylene.
• Suitable polyesters include fiber forming polyesters known in the art.
• the polyester resin may be selected from the group consisting of polyethylene terephthalate (PET), polybutylene terephthalate, polytrimethylene terephthalate, polyethylene naphthalate, polylactic acid (PLA) and blends or copolymers thereof.
• the first fiber forming polymer is present in the synthetic fiber in a range from about 90 to 99 percent by weight.
• Patent 6,680,018 disclose a similar composition and method wherein the stain resistance of polyamide fibers is improved by melt compounding a combination of sulfonated polyester concentrate and thermoplastic carrier resin with fiber-forming polyamide compositions subsequent to polymerization of the polyamide and prior to the formation of the fibers.
• the synthetic fiber of this embodiment further comprises a soil resistance-affecting additive.
• the soil resistance-affecting additive is an aromatic sulfonate or an alkali metal salt thereof Nonlimiting examples include 5-sulfoisophthalic acid, sodium salt (SSIPA) and dimethyl-5-suIfoisophthalate, sodium salt (NaSIM).
• the soil resistance-affecting additive is a polymer.
• a nonlimiting example of a polymer useful as a soil resistance-affecting additive in this embodiment is polypropylene.
• the soil resistant additive is present in the synthetic fiber in a range from about 0.1 to about 10 percent by weight.
• the synthetic fiber of the present disclosure comprises a first fiber forming polymer, a second polymer and a soil resistance-affecting additive.
• first fiber forming polymers which can be used in this embodiment include, but are not limited to, polyamides, polyesters, and polyolefins and any blends or combinations thereof.
• Suitable polyamides include fiber forming polyamides known in the art to be suitable for the formation of bulked continuous filament fibers, having sufficient viscosity, tenacity, chemical stability and crystallinity to be at least moderately durable in such application.
• the polyamide may be selected from the group consisting of nylon 5,6; nylon 6,6; nylon 6; nylon 7; nylon 11; nylon 12; nylon 6/10;, nylon 6/12; nylon DT; nylon 6T; nylon 61; and blends or copolymers thereof.
• the polyamide is nylon 6,6 polymer.
• Suitable polyolefins include polypropylene.
• Suitable polyesters include fiber forming polyesters known in the art.
• the polyester resin may be selected from the group consisting of polyethylene terephthalate, polybutylene terephthalate, polytrimethylene terephthalate, polyethylene naphthalate, polylactic acid (PLA) and blends or copolymers thereof.
• the first fiber forming polymer is present in the synthetic fiber in a range from about 80 to 99 percent by weight.
• the synthetic fiber of this embodiment further comprises a soil resistance-affecting additive.
• the soil resistance-affecting additive is an aromatic sulfonate or an alkali metal salt thereof.
• Nonlimiting examples include 5-sulfoisophthalic acid, sodium salt and dimethyl-5-sulfoisophthalate, sodium salt.
• the soil resistant additive is present in the synthetic fiber in a range from about 0.1 to about 10 percent by weight.
• the synthetic fiber of this embodiment further comprises a second polymer.
• the second polymer having a melting point that is less than the melting point of the first fiber forming polymer.
• the presence of the second polymer does not cause the synthetic fiber to fibrillate.
• second polymers useful in the present disclosure include, but are not limited to, polyolefins, polylactic acid and polystyrene, or any blend or combination thereof.
• the polyolefin is an unmodified polyolefin.
• the second polymer is polypropylene.
• the second polymer is present in the synthetic fiber in a range from about 0.5 to about 10 percent by weight.
• at least a portion of the soil resistance- affecting additive is present on the surface of the fiber. Preferred is that this portion present on the surface of the fiber is sufficient to impart soil resistant properties to the fiber.
• At least a portion of the soil resistance- affecting additive is not polymerized with the first fiber forming polymer. Instead, preferred in the synthetic fibers of this disclosure is that at least a portion of the soil resistance-affecting additive has bloomed to the surface of the fiber.
• the synthetic fiber of this disclosure has a multilobal cross section.
• a majority meaning greater than 50%
• at least 75% or substantially all of the soil resistant additive present on the surface of the fibers is located in the area between the lobes.
• the present disclosure also relates to articles of manufacture comprising at least a poition of a synthetic fiber or fibers of this disclosure.
• articles of manufacture include, but are not limited to, yarns prepared from the synthetic fibers, as well as fabrics and carpets prepared from the synthetic fibers and/or yarns.
• Also provided by this disclosure are processes for forming these synthetic fibers with enhanced soil resistance.
• the process comprises forming a polymer melt comprising a first fiber forming polymer and a soil resistance-affecting additive.
• the soil resistance-affecting additive is present in a range from about 0.1 to 10 percent by weight.
• a synthetic fiber is then formed from the polymer melt.
• the soil resistance-affecting additive used in the process can be an aromatic sulfonate or an alkali metal salt thereof, or a polymer.
• Nonlimiting examples include 5- sulfoisophthalic acid, sodium salt; dimethyl-5-sulfoisophthalate, sodium salt; and polypropylene.
• the soil resistance-affecting additive is added to the polymer melt by powder addition. In another nonlimiting embodiment, the soil resistance- affecting additive is added as a powder capsule.
• the process comprises forming a polymer melt comprising a first fiber forming polymer and a masterbatch compound.
• the masterbatch compound comprises a second polymer and a soil resistance- affecting additive.
• the first fiber forming polymer is present in a range from about 80 to 99 percent by weight, and the masterbatch compound is present in a range from about 1 to 20 percent by weight.
• no additional steps are required to remove volatiles while forming the polymer melt.
• a synthetic fiber is then formed from this polymer melt.
• the soil resistant additive used in the process can be an aromatic sulfonate or an alkali metal salt thereof. Nonlimiting examples include 5-sulfoisophthalic acid, sodium salt and dimethyl-5-sulfoisophthalate, sodium salt.
• the masterbatch compound comprises a thermoplastic carrier, also referred to herein as second polymer.
• thermoplastic carriers useful in the masterbatch include, but are not limited to polyolefins, polylactic acid, polystyrene, or a blend or copolymer thereof.
• the thermoplastic carrier is a polyolefin.
• the thermoplastic carrier is an unmodified polyolefin.
• the thermoplastic carrier is polypropylene.
• thermoplastic carrier is present in the masterbatch compound in a range from about 40 to about 90 percent by weight. In one nonlimiting embodiment, the masterbatch compound comprises about 50% of the thermoplastic carrier.
• the masterbatch compound further comprises a soil resistance-affecting additive.
• Suitable soil resistance-affecting additives include, but are not limited to aromatic sulfonates and alkali metal salts thereof, such as 5-sulfoisophthalic acid, sodium salt and dimethyl-5- sulfoisophthalate, sodium salt.
• the soil resistance-affecting additive is present in the masterbatch compound in a range from about 10 to about 60 percent by weight.
• the masterbatch compound has a moisture content less than about 200 ppm, more preferably less than about 50 ppm. In another nonlimiting embodiment,
• the masterbatch compound is not dried or conditioned prior to forming the polymer melt.
• the masterbatch compound may further comprise other additives, to be used to confer additional benefits to articles upon polymer melt extrusion and melt spinning.
• additives are inorganic pigments, and ultraviolet (UV) light absorbers or optical brightening agents.
• UV light absorbers or optical brightening agents examples include titanium dioxide, barium sulfate, carbon black, manganese dioxide, and zinc oxide.
• UV light absorbers or optical brightening agents examples include 2,2'-(l ,2-ethenediyldi-4,l phenylene)bisbenzoxazole, available commercially by Eastman Chemical Company under the tradename Eastobrite® OB-1, and 2,2'-(2 ,5- thiophenediyl)bis(5-tert-butylbenzoxazole, available commercially by Mayzo, Inc. under the tradename Benetex® OB.
• the masterbatch compound is present in fiber in a range from about 1 to about 20 percent by weight.
• the present disclosure also relates to articles of manufacture, at least a portion of which comprises a synthetic fiber produced in accordance with this process.
• Nonlimiting examples include yams prepared from synthetic fibers produced by this process, as well as fabrics and carpets prepared from these synthetic fibers and/or yarns.
• masterbatches were prepared with the following soil resistance-affecting additives:
• the masterbatches were added at the extruder hopper to a standard bottle-grade PET resin, at 0.5 wt% and 2 wt% actives.
• the resultant pigmented trilobal PET fibers were processed and tufted into a 30 oz./sq. yd residential cut pile carpet. It was found that the characteristic stain resistance of PET was not negatively impacted by blending with the soil resistant additive.
• a filament in accordance with the present disclosure has an exterior modification ratio (R2/R1) that can be about 1.50 to 3.00, and more particularly can be about 2.15 to 2.85.
• the modification ratio (MR) for the control items was nominally the same, at 2.5.
• Modification ratio determinations, in particular for triloba! bulked continuous filaments, are described as disclosed in European Patent 1,518,948, and U.S. Patent Publication 2015 0275400.
• the synthetic fibers of this disclosure were found to have markedly improved soiling performance in carpet form.
• Carpets produced from these synthetic fibers have a "built- in,” or fiber bound, anti-soil performance that exceeds current fluorochemical-based topical anti- soil treatment in efficacy.
• this built-in resistance is more durable than topical treatments for anti-soil which are known to "walk off with wear and foot traffic so that the topical chemistry is no longer effective.
• using the synthetic fibers of this disclosure ehminates the need for topical application of chemicals by downstream carpet mills. Use of a non-fluoiinated compound to enhance soil resistance also diminishes possible environmental concerns.
• Accelerated drum soiling is recorded as Delta E, and measured according to ASTM D6540. Within the reproducibility limitations of this test, the relative soiling performance of variously-treated samples may be determined.
• the test simulates the soiling of carpet in residential or commercial environments to a traffic count level of about 100,000 to 300,000. According to ASTM D6540, soiling tests can be conducted on up to six carpet samples simultaneously using a drum.
• the base color of the sample (using the L, a, b color space) is measured using the hand held color measurement instrument sold by Minolta Corporation as "Chromameter" model CR-310 (at Camden). This measurement output is in the form L*, a* and b* values and describes a color value in color space. This is the original color value.
• the carpet sample is mounted on a thin plastic sheet and placed in the drum. Two hundred fifty grams (250 g) of dirty Zytel 101 nylon beads (by DuPont Canada, Mississauga, Ontario) are placed on the sample.
• the dirty beads are prepared by mixing ten grams (10 g) of AATCC TM-122 synthetic carpet soil (by Manufacturer Textile Innovators Corp., Windsor, N.C.) with one thousand grams (1000 g) of new Nylon Zytel 101 beads.
• One thousand grams (1000 g) of 3 ⁇ 4-inch diameter steel ball bearings are added into the drum. The drum is run for 30 minutes with direction reversal and the sample removed. After removal the carpet is cleaned with a vacuum cleaner and the chromameter is used again to measure the color of the carpet after cleaning.
• the difference between the color measurements of each carpet is the total color difference, ⁇ *, and is based on L*, a*, and b* color differences in color space, known to those skilled in the field where
• AATCC TM175 - Stain Resistance Pile Floor Coverings
• Comparative Examples 1 , 2, and 5 and Examples 3, 4, 6, and 7 were produced using pilot scale machinery.
• the pilot equipment included a 12" twin screw extruder having five heating zones, a filter screen pack, any of a selection of desired spinnerets, a fiber quenching zone, godet rolls, and winders.
• a standard spinning method was used to produce fiber from the pilot scale machinery, as follows: the polymer was extruded through the spinnerets and divided into two 184 filament segments. The molten fibers were then rapidly quenched in a chimney, where cooling air at about 10— 15 °C was blown past the filaments at four hundred and fifty cubic feet per minute [300-600 cfm] through the quench zone.
• the filaments were then coated with a lubricant for drawing and crimping.
• the coated yarns were drawn at about 2422 yards per minute (2.9x draw ratio) using a pair of heated draw rolls.
• the draw roll temperature was 160° C.
• the filaments were then forwarded into a dual-impingement hot air bulking jet, similar to that described in Coon, U.S. Patent 3,525,134, teachings of which are herein incorporated by reference, to form two BCF yarns (1000 denier, 5.4 dpi).
• the temperature of the air in the bulking jet was 180 °C.
• Comparative Example 1 PET BCF, no melt additive, no topical anti-soil treatment
• PET bulked continuous filament (BCF, 1000 denier, 184 filaments) was made on pilot scale machinery. Pigments of various colors were mixed with a PET polymer product made by Indorama, Spartanburg, SC, USA. The pigments and PET were mixed at the screw feeder. Fibers were spun with no process breaks. This BCF yarn had a wool beige color. It was tufted into carpet having 1 ⁇ 2" pile height, 16 stitches per inch, 30 oz per square yard cut pile carpet on a 1/8 gauge ftifting machine. The carpet was tested for accelerated soiling, stain repellency, and wear resistance as shown in Table 1 and the FIGs 1-2.
• Comparative Example 2 PET BCF, no melt additive, treated with topical soil resist
• PET bulked continuous filament (BCF, 1000 denier, 184 filaments) was made on pilot scale machinery. Pigments of various colors were mixed with a PET polymer product made by Indorama, Spartanburg, SC, USA. The pigments and PET were mixed at the screw feeder. Fibers were spun with no process breaks. This BCF yarn had a wool beige color.
• Example 3 PET BCF, masterbatch additive, 1.0 wt% masterbatch
• PET bulked continuous filament (BCF, 1000 denier, 184 filaments) was made on pilot scale machinery.
• the masterbatch and PET were mixed at the screw feeder. Fibers were spun with no process breaks.
• This BCF yarn had a wool beige color. It was tufted into carpet having 1 ⁇ 2" pile height, 16 stitches per inch, 30 oz per square yard cut pile carpet on a 1/8 gauge tufting machine. The carpet was tested for accelerated soiling, stain repellency, and wear resistance as shown in Table 1 and FIGs 1-2.
• Example 4 PET BCF, masterbatch additive, 4 wt% masterbatch
• PET bulked continuous filament (BCF, 1000 denier, 184 filaments) was made on pilot scale machinery.
• the masterbatch and PET were mixed at the screw feeder. Fibers were spun with no process breaks.
• This BCF yarn had a wool beige color. It was tufted into carpet having 1 ⁇ 2" pile height, 16 stitches per inch, 30 oz per square yard cut pile carpet on a 1/8 gauge tufting machine. The carpet was tested for accelerated soiling, stain repellency, and wear resistance as shown in Table 1 and FIGs 1-2.
• Comparative Example 5 PET BCF, no melt additive, treated with topical soil resist, 50 oz/yd 2 carpet
• PET bulked continuous filament (BCF, 1000 denier, 184 filaments) was made on pilot scale machinery. Pigments of various colors were mixed with a PET polymer product made by Indorama, Spartanburg, SC, USA. The pigments and PET were mixed at the screw feeder. Fibers were spun with no process breaks. This BCF yam had a wool beige color. It was tufted into carpet having 1 ⁇ 2" pile height, 50 oz per square yard cut pile carpet on a 1/8 gauge tufting machine and an anti-soil treatment was applied by spraying the tufted carpet with an anti-soil chemistry comprising clay nanoparticles (Laponite ®) and fluorochemicals (Capstone® RCP) at 1.2% owf. The carpet was tested for accelerated soiling, stain repellency, and wear resistance as shown in Table 1 and FIGs 1-2.
• Example 6 PET BCF, masterbatch additive, 1.0 wt% masterbatch
• PET bulked continuous filament (BCF, 1000 denier, 184 filaments) was made on pilot scale machinery.
• the masterbatch and PET were mixed at the screw feeder. Fibers were spun with no process breaks.
• This BCF yarn had a wool beige color. It was tufted into carpet having 1 ⁇ 2" pile height, 50 oz per square yard cut pile carpet on a 1/8 gauge tufting machine. The carpet was tested for accelerated soiling , stain repellency, and wear resistance as shown in Table 1 and FIGs 1-2.
• Example 7 PET BCF, masterbatch additive, 4 wt% masterbatch
• PET bulked continuous filament (BCF, 1000 denier, 184 filaments) was made on pilot scale machinery.
• the masterbatch and PET were mixed at the screw feeder. Fibers were spun with no process breaks.
• This BCF yarn had a wool beige color. It was tufted into carpet having 1 ⁇ 2" pile height, 50 oz per square yard cut pile carpet on a 1/8 gauge tufting machine.
• the caipet was tested for accelerated soiling, stain repellency, and wear resistance as shown in Table 1 and FIGs 1-2.

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• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• General Chemical & Material Sciences (AREA)
• Mechanical Engineering (AREA)
• Manufacturing & Machinery (AREA)
• Artificial Filaments (AREA)

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• 2016
  • 2016-05-05 AU AU2016258018A patent/AU2016258018B2/en not_active Ceased
  • 2016-05-05 CN CN201680026259.0A patent/CN108138369A/zh active Pending
  • 2016-05-05 WO PCT/US2016/030967 patent/WO2016179384A1/en active Application Filing
  • 2016-05-05 EP EP16727002.4A patent/EP3292234A1/en not_active Withdrawn
  • 2016-05-05 JP JP2018510320A patent/JP2018515701A/ja active Pending
  • 2016-05-05 CA CA2985101A patent/CA2985101A1/en not_active Abandoned
  • 2016-05-05 US US15/570,784 patent/US20180119310A1/en not_active Abandoned

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